The fabrication of beryllium. Volume VI - Joining techniques for beryllium alloys
Joining techniques and structural stability of beryllium alloys for fabricating aerospace vehicles
STRUCTURAL STABILITY↗
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Translation of "Contribution a l'etude du diagramme pression-temperature du beryllium pur" (Contribution to the Study of the Pressure-Temperature Diagram of Pure Beryllium)
An unusual feature of beryllium’s phase diagram is the transition from a hexagonal close packed (hcp, or α) to a body-centered cubic (bcc, or β) structure ~20 K below the normal melting temperature of T melt ≈ 1560 K. An early thermal analysis of 99.7% pure Be found two arrests1 : one at 1533-1536 K and another at 1551-1557 K. Without ruling out an allotropic transformation in Be itself, Sloman attributed the first of these to solidification of a Be-BeO eutectic. Losano observed only the higher of the two in 99.962% Be, seeming to confirm the notion that the lower feature was an artifact of impurity. Teitel (99.4%) also measured two arrests and attributed the lower to impurity, but questioned whether oxygen was the culprit.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Beryllium fluoride coating as a corrosion retardant for beryllium.
High temperature modified Be fluoride, rhombic tridymite, protects Be against aqueous corrosion
Odonnell, P. M.↗
The behavior of beryllium and beryllium copper in a 4,000 F supersonic air jet at a Mach number of 2
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Kinard, William H↗
Modeling and Analysis of the Transport and Disposal of Beryllium Moderator Blocks and Greater than Class C (GTCC) Waste
Radioactive waste in the United states is categorized based on its source, radioactivity, and security risk. The categorization method employed by the Nuclear Regulatory Committee (NRC) for low-level radioactive waste is not currently applied to any waste generated by the Department of Energy (DOE) or disposed of in DOE facilities. As a result, there is a large volume of DOE-generated waste with characteristics similar to the NRC’s “Greater than Class C” (GTCC) waste category which presently do not have a path for long-term disposal. Much of this waste cannot undergo the standard commercial disposition process due to it being categorized as Transuranic (TRU) waste under DOE guidelines, due to elevated concentrations of key fission products. Possible solutions to this dilemma are explored in the Environmental Impact Statement for the “Disposal of Greater-Than-Class-C Low Level Radioactive Wave” (EIS-0375). This paper analyzes several EIS possible paths for disposal for this “orphaned” waste. One example that highlights this categorization issue is the spent beryllium cladding that has been extracted from the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) throughout its operational lifetime. These beryllium blocks surround the reactor’s main chambers and components and serve as neutron moderators. This paper will use this particular waste form to analyze the economic and technological viability of transporting and storing this material under the storage and transportation criteria of the Waste isolation Pilot Plant (WIPP), which was deemed the most feasible disposition path according to the EIS. The example of this waste form used in this paper that highlights this categorization issue is the spent beryllium cladding extracted from Idaho National Laboratory’s (INL) Advanced Test Reactor (ATR). These beryllium blocks surround the reactor’s components and serve as neutron moderators, and thus have accumulated high concentration of high-activity transuranic isotopes. This paper analyzed the viability of transporting and storing this material under the storage and transportation criteria of the five primary disposition paths covered in EIS-0375. An array of calculations was carried out to assess the viability of the various disposition paths for the beryllium shipments as well as other waste shipments that fall within the GTCC category. Modeling with MCNP 6.2 was conducted to determine whether the beryllium blocks could be safely stored and transported within a 72-B cask; the standard shipping container for remote-handled, transuranic waste, while also meeting regulatory limits at various disposition paths. A cost analysis of the transportation and long-term disposal paths mentioned in the EIS was also carried out using available data and information from similar waste shipments. Lastly, a geochemical analysis of the various geological repository discussed in the EIS was also carried out using the Geochemists Workbench Release 14. Long-term disposal of the beryllium blocks at the Waste Isolation Pilot Plant (WIPP) proved to be the most cost-effective long-term disposition option of the ones considered in the EIS. A dose rate calculation at both contact and remote-handling distances indicate that the analyzed beryllium shipments should not exceed the exposure limits at any of the considered locations. Greater-than-class-C waste has been left in a regulatory state of limbo for years, resulting in backlogs of inventory across several research sites in the United States. Due to its high activity and presence of transuranic isotopes, it is imperative to ensure that it remains inaccessible and sequestered both in its short-term interim as well as a long-term geologic time scale. The information and assessments done in the paper could potentially serve as a reference for any future shipments of this waste form at the WIPP facility as well as other disposition paths that may be considered in the future.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Data on erosion and hydrogen fuel retention in Beryllium plasma-facing materials
ITER will use beryllium as a plasma-facing material in the main chamber, covering a total surface area of about 620 m 2 . Given the importance of beryllium erosion and co-deposition for tritium retention in ITER, significant efforts have been made to understand the behaviour of beryllium under fusion-relevant conditions with high particle and heat loads. This paper provides a comprehensive report on the state of knowledge of beryllium behaviour under fusion-relevant conditions: the erosion mechanisms and their consequences, beryllium migration in JET, fuel retention and dust generation. The paper reviews basic laboratory studies, advanced computer simulations and experience from laboratory plasma experiments in linear simulators of plasma–wall interactions and in controlled fusion devices using beryllium plasma-facing components. A critical assessment of analytical methods and simulation codes used in beryllium studies is given. The overall objective is to review the existing set of data with a broad literature survey and to identify gaps and research needs to broaden the database for ITER.
Erosion–deposition↗
A laboratory-scale process for producing dilithium beryllium tetrafluoride (FLiBe) with dissolved uranium tetrafluoride
Flibe Energy, Incorporated (FEI)'s conceptual Lithium Fluoride Thorium Reactor (LFTR) incorporates a chemical processing facility aimed at recovering uranium and other valuable volatile radionuclides while managing harmful radionuclides from the used fuel. The fuel utilized in this reactor is a combination of dilithium beryllium tetrafluoride (Li 2 BeF 4 or FLiBe) and uranium tetrafluoride (UF 4 ), (FLiBe/U). FEI's plan involves extracting the uranium and other valuable volatile fluoride-forming radionuclides using nitrogen trifluoride (NF 3 ). To facilitate laboratory-scale testing of uranium extraction using NF 3 and address the toxicity and physical hazards associated with beryllium and beryllium fluoride (BeF 2 ), we used a two-step process to prepare the simulated fuel salt. The first step entailed thermally decomposing ammonium beryllium tetrafluoride [(NH 4 ) 2 BeF 4 ] (ABeF) through a nominal 3-step process, combined with appropriate amounts of lithium fluoride (LiF) and UF 4 , resulting in the formation of beryllium fluoride (BeF 2 ). In the second step, the mixture was repeatedly melted and frozen at the melting point of FLiBe to prepare the eutectic FLiBe with dissolved UF 4 . Although the concept appears straightforward, the production of FLiBe/U involved various challenges. These challenges included transporting the gaseous decomposition products of ABeF, hydrogen fluoride (HF) and ammonia (NH 3 ), while preventing the formation of ammonium fluoride (NH 4 F). Additionally, it was necessary to control the reaction between the higher-than-anticipated water content in the commercial ABeF with NH 3 , HF, and the condensed NH 4 F, protect UF 4 from forming an unknown black compound, select suitable structural materials to mitigate fluoride corrosion, address the risks associated with beryllium toxicity through equipment design and operational protocols, and monitor process conditions. This article provides an account of the thermal decomposition chemistry observed in the commercial ABeF, describes the FLiBe/U production apparatus, describes the experiences and process refinements developed to prepare FLiBe/U, and presents our characterizations of prepared FLiBe/U.
Ammonium beryllium fluoride thermal decomposition↗
Beryllium Isotopes in Rainfall for Stratospheric-Tropospheric Exchange Dynamics Experiment (BIRDIE) (Final Report)
The Beryllium Isotopes in Rainfall for Stratospheric-Tropospheric Exchange Dynamics Experiment or BIRDIE was a precipitation collection campaign designed to measure cosmogenic isotopes of beryllium in rainfall and other forms of precipitation across the DOE Southern Great Plains (SGP) Atmospheric Radiation Measurement (ARM) site. Precipitation samples were collected over three weeks (May 21-June 10, 2022) at 11 SGP sites across a 120 km 2 domain in northern and central Oklahoma. The field campaign targeted summer-time convection rain events. We aimed to capture any spatial and/or temporal variability in the concentrations of beryllium-10 (10Be) and beryllium-7 (7Be) across the SGP ARM site during these rainfall events. The ratio of 10Be to 7Be (10/7Be) has been shown to be a powerful tracer for transport processes in the stratosphere-troposphere exchange (STE) system (e.g., Koch and Rind 1998). Any observed variability is analyzed to see if it could be linked to STE processes, including overshooting of deep convection clouds which penetrate the lower stratosphere. Six wet weather system events were collected within our three-week span. Five out of six of these rainfall events are classified as moderately to strongly convective. Those events are studied in more detail. The five systems also follow each other over a short time period of eleven days. In our rainfall samples we observed spatial and event variability in the concentrations of beryllium-10 and -7 which resulted in variability of 10/7 Be ratios. Each weather event appeared to exhibit a unique 10/7Be pattern across the domain that was not directly linked to storm total precipitation amount. To better understand the causes for this spatial variability, cloud characteristics in the domain were looked at to assess cloud type, cloud height and depth information. We also ran Hysplit back trajectories to identify possible air mass and moisture origins across our events. Detailed analysis is still on-going. The purpose of this technical report is to provide background on using cosmogenic isotopes as atmospheric tracers, describe the experimental design, and present the beryllium concentration and ratio data.
58 GEOSCIENCES↗
Beryllium Isotopes in Rainfall for Stratospheric-Tropospheric Exchange Dynamics Experiment (BIRDIE) (Field Campaign Report)
The Beryllium Isotopes in Rainfall for Stratospheric-Tropospheric Exchange Dynamics Experiment or BIRDIE was a precipitation collection campaign designed to measure cosmogenic isotopes of beryllium in rainfall and other forms of precipitation across the U.S. Department of Energy Atmospheric Radiation Measurement (ARM) user facility’s Southern Great Plains (SGP) atmospheric observatory. Precipitation samples were collected over three weeks (May 21-June 10, 2022) at 11 SGP sites across a 120-km 2 domain in northern and central Oklahoma. The field campaign targeted summertime convection rain events. We aimed to capture any spatial and/or temporal variability in the concentrations of beryllium-10 (10Be) and beryllium-7 (7Be) across the ARM SGP site during these rainfall events. The ratio of 10Be to 7Be (10/7Be) has been shown to be a powerful tracer for transport processes in the stratosphere-troposphere exchange (STE) system (e.g., Koch and Rind 1998). Any observed variability is analyzed to see if it could be linked to STE processes, including overshooting of deep convection clouds that penetrate the lower stratosphere. Six wet weather system events were collected within our three-week span. Five out of six of these rainfall events are classified as moderately to strongly convective. Those events are studied in more detail. The five systems also follow each other over a short period of 11 days. In our rainfall samples we observed spatial and event variability in the concentrations of beryllium-10 and -7 that resulted in variability of 10/7Be ratios. Each weather event appeared to exhibit a unique 10/7Be pattern across the domain that was not directly linked to storm total precipitation amount. To better understand the causes for this spatial variability, cloud characteristics in the domain were looked at to assess cloud type, cloud height, and depth information. We also ran Hybrid Single-Particle Lagrangian Integrated Trajectory (HYSPLIT) model back trajectories to identify possible air mass and moisture origins across our events. Detailed analysis is ongoing. The purpose of this technical report is to provide background on using cosmogenic isotopes as atmospheric tracers, describe the experimental design, and present the beryllium concentration and ratio data. Lastly, we note that BIRDIE coincided with two other deep convection field campaigns in the area: The National Aeronautics and Space Administration (NASA)’s Dynamics and Chemistry of the Summer Stratosphere (DCOTSS) experiment (https://dcotss.org/) centered in Salina, Kansas, and the Targeted Observation by Radars and (uncrewed aerial systems) UAS of Supercells (TORUS) experiment (https://catalog.eol.ucar.edu/torus_2022) across the U.S. Central Plains. Additionally, a Lawrence Livermore National Laboratory ( LLNL) team at DCOTSS attempted to measure 10Be/7Be ratios on aerosols collected in situ in the lower and mid-stratosphere over Kansas using high-altitude balloons. Precipitation samples were also collected on the ground in Salina, Kansas.
54 ENVIRONMENTAL SCIENCES↗
Beryllium heat shield technology in the area of thermal protection devices
For future space applications, it is important that thermal protection systems be reusable for space shuttle flights. Beryllium offers a unique combination of properties for use as a heat shield material (stiffness, lightweight, ability to absorb heat). In order to adequately test these properties, it was necessary to fabricate heat shields. The concept used was a two-section test panel 99.1 x 99.1 cm (39 x 39 inch) with each section made of two 0.051 cm (0.020 inch) thick beryllium corrugations brazed together as a mirror image, with titanium (Ti-6Al-4V) used as standoffs to support the panel structure. The work prior to fabrication included brazability of both beryllium and titanium, forming of beryllium and titanium, machining processes involving beryllium and chem-milling beryllium. Sub-scale samples were made of all details before actual fabrication of the large panel. The full scale test panel was hot-formed at 950 K, chem-milled to 0.041 + or - 0.005 cm (0.016 + or - 0.002 inches), trimmed, vacuum brazed, drilled and assembled.
Muhl, A. E.↗
BERYLLIUM DETECTION BY FLUORESCENT SPECTROSCOPY
Facilities that machine and process materials involving beryllium oxide are hazardous to workers safety and require monitoring of contamination. A primary goal in industrial worker safety in beryllium containing facilities is avoiding inhalation, which may cause chronic beryllium disease (CBD). Decontamination is labor intensive due to the miniscule size of beryllium dust and the difficulty of detecting its presence on surfaces. Current methods of beryllium detection, while successful, involve numerous intermediate steps such as obtaining wipe samples, applying buffers, centrifuging with ammonium bifluoride, additives to reduce influence of other competing metal ions, and require potentially long wait times of around 24 hours for a single surface sample. In some cases, these samples must be sent to testing facilities across the country and results may not be available for days. Therefore, for the purposes of this study, it has been deemed important to test new fluorescent dyes that can rapidly produce a beryllium presence confirmation via application spray.
61 RADIATION PROTECTION AND DOSIMETRY↗
BIRDIE beryllium-10 and -7 measurements from 2022 summer deep convection rain at ARM SGP
Water samples were manually collected from 11 SGP ARM sites in the early summer of 2022 to measure cosmogenic isotopes of beryllium. The water samples were brought back to the Center for Accelerator Mass Spectrometry (CAMS) at LLNL and analysed for beryllium-10 and beryllium-7 as well as for chlorine-37, chlorine-36, and tritium. A total of six storm events were measured over three weeks. At least five of those storms included overshooting cloud events. Available data include precipitation amount, beryllium-10 concentration, beryllium-7 concentration, and 10/7Be ratio. Spatial and temporal variability in the cosmogenic isotopes was relatively high but could not directly be linked to precipitation amount. Analysis is on-going to explain the measured variability and to see if it can be linked to cloud top height and overshooting depth.
54 ENVIRONMENTAL SCIENCES↗
Experimental observation and integrated modelling of proton-beryllium fusion in He and D plasmas at JET
Validated integrated modelling of JET ITER-like wall experiments in which fusion performance is driven by reactions between fast ions and intrinsically present metal wall impurities is presented. A steady-state L-mode plasma with dominant proton-beryllium fusion and neutron yields of up to ≈ 6·10 13 s -1 is developed in He and D, via radiofrequency heating of a H minority. The fusion drive is unambiguously confirmed by the neutral particle analyser, fast ion loss detector, and γ-ray diagnostics. Experiments are analysed via an integrated modelling framework, developed to model the two-stage proton beryllium-fusion chain and produce high-fidelity fusion product source terms. The modelling chain comprises TRANSP and JETTO for plasma core modelling, LOCUST for full orbit product tracking and collisional slowing-down, DRESS to resolve two- and three-body fusion kinematics, and MCNP for neutron transport calculations. Modelling shows that the primary 9 Be(p,n) 9 B reaction is the dominant neutron emitter at naturally present concentrations of beryllium in these experiments. The yield contribution of secondary reactions between fusion products and beryllium, 9 Be(d,n) 10 B and 9 Be(α,n) 12 C, is found to be negligible. The proton-deuteron knock-on effect in D plasmas is modelled, which is calculated to contribute ≈ 25% to the total neutron yield. For both He and D discharges the total computed neutron rates match fission chamber (FC) measurements within the combined experimental and computational uncertainty, with an average discrepancy of ≈ ± 20%. Realistic proton-beryllium neutron sources are propagated through JET’s MCNP neutron transport model which shows that 235 U FCs’ response is sensitive to p–Be source changes, with up to ≈ 10% variation compared to a D–D neutron source. We show that the high-energy tail of the fast proton minority can be studied with multi-foil neutron activation. The framework is also applied to the study of interactions between fast protons and boron impurities, of relevance to ITER. We calculate that in JET conditions a significant alpha source with DT-like energies could be generated through 11 B(p, α)2α fusion, and detected via γ-emission in secondary interactions between fast alphas and boron. The work represents an important step towards validating predictive integrated modelling capabilities for non-standard fusion reactions.
JET↗
Beryllium disease among construction trade workers at Department of Energy nuclear sites: A follow‐up
Abstract Background Construction workers at U.S. Department of Energy (DOE) nuclear weapons facilities are screened to identify DOE‐related occupational illnesses, including beryllium sensitization (BeS) and chronic beryllium disease (CBD). The study objectives were to estimate beryllium disease risks and the CBD claims acceptance rate in the energy workers' benefits program. Methods Workers diagnosed with BeS via beryllium lymphocyte proliferation test (BeLPT) included in screening examinations were interviewed about subsequent diagnosis of CBD. We estimated the proportion who developed CBD based on the ratio of CBD cases, based on self‐reported compensation claim status, to all workers with BeS interviewed. We used stratified analyses to explore trends in disease frequency by age, race, sex, DOE employment duration, site, trade group, and cigarette smoking history. Results Between 1998 and 2020, 21,854 workers received a BeLPT; 262 (1.20%) had BeS (two abnormals or one abnormal plus one borderline test); 212 (0.97%) had a single abnormal BeLPT. Of 177 BeS workers interviewed, 35 (19.8%) reported an accepted CBD compensation claim. The claims acceptance rate among BeS workers increased with years of DOE employment, from 8.4% with <5 years to 33.3% for >25 or more years. Five of 68 interviewed workers with a single positive BeLPT reported CBD claim acceptance; an additional CBD case was confirmed by chart review (8.8%). Conclusions Years of DOE work predict the risk of developing CBD among those sensitized and getting a claim for CBD accepted. Ongoing surveillance and increased awareness of the risk of beryllium exposure and CBD as an occupational disease among construction workers are needed.
Cloeren, Marianne↗
Reactor Performance and Safety Characteristics of Beryllium-Based Composite Moderators as Replacements for Graphite in mHTGRs
Here, this study evaluates beryllium-based two-phase composite moderators as an alternative to graphite in an evaluation of reactor performance and safety characteristics. Historically, modular high-temperature gas-cooled reactors (mHTGRs) use graphite as a moderator because of its high moderating ratio and reasonable thermal properties; however, graphite has unfavorable properties under irradiation, which can require component replacement and a significant radioactive waste burden. In this assessment, we explore advanced moderators comprised of magnesium oxide (MgO) as the host matrix and beryllium metal and/or beryllium oxide (Be and/or BeO) as the entrained moderating phase. For the reactor performance and thermal-hydraulic safety analysis, the core design model of the General Atomics mHTGR-350 was used to demonstrate the feasibility of a “drop-in” replacement of graphite using the beryllium-based moderators. We employed the neutronics code Serpent to analyze the moderating behavior of the composite moderators with comparisons drawn to graphite. We performed a scoping analysis of accidents for mHTGRs using RELAP to show that these moderators do not present impediments to safety and are expected to stay within temperature limits. Measured thermophysical properties of the composite moderators are used in the thermal-hydraulic assessments. Our analysis reveals that the two-phase composite MgO-matrix beryllium-based moderators are a suitable replacement for graphite.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Beryllium-driven structural evolution at the divertor surface
Erosion of the beryllium first wall material in tokamak reactors has been shown to result in transport and deposition on the tungsten divertor. Experimental studies of beryllium implantation in tungsten indicate that mixed W–Be intermetallic deposits can form, which have lower melting temperatures than tungsten and can trap tritium at higher rates. To better understand the formation and growth rate of these intermetallics, we performed cumulative molecular dynamics (MD) simulations of both high and low energy beryllium deposition in tungsten. In both cases, a W–Be mixed material layer (MML) emerged at the surface within several nanoseconds, either through energetic implantation or a thermally-activated exchange mechanism, respectively. While some ordering of the material into intermetallics occurred, fully ordered structures did not emerge from the deposition simulations. Targeted MD simulations of the MML to further study the rate of Be diffusion and intermetallic growth rates indicate that for both cases, the gradual re-structuring of the material into an ordered intermetallic layer is beyond accessible MD time scales(≤1 μs). However, the rapid formation of the MML within nanoseconds indicates that beryllium deposition can influence other plasma species interactions at the surface and begin to alter the tungsten material properties. Therefore, beryllium deposition on the divertor surface, even in small amounts, is likely to cause significant changes in plasma-surface interactions and will need to be considered in future studies.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Containerless processing of beryllium
Melting and solidification of a beryllium alloy containing 1.5% BeO by weight in the weightless environment of space has produced cast beryllium with a relatively uniform dispersion of BeO throughout. Examination of the cast material shows that it is coarse grained, although the BeO is not heavily agglomerated in the flight specimen. Ground based comparison experiments show extreme agglomeration and segregation of BeO, resulting in large zones which are practically free of the oxide. Several postulated hypotheses for the failure to grain refine the beryllium are formulated. These are: (1) spherodization of the BeO particles during specimen preparation and during the molten phase of the experiment; (2) loss of nucleation potency through aging in the molten phase; and (3) inability of BeO to act as a grain refiner for beryllium. Further investigation with non spherodized particles and shorter dwell times molten may delineate which of these hypotheses are valid. The results of this flight experiment indicate that the weightless environment of space is an important asset in conducting research to find grain refiners for beryllium and other metals for which cast dispersions of grain refining agents cannot be prepared terrestrially due to gravitationally driven settling and agglomeration.
Wouch, G.↗
The BIRDIES Experiment: Measuring Beryllium Isotopes to Resolve Dynamics in the Stratosphere
Cosmogenic beryllium-10 and beryllium-7, and the ratio of the two (10Be/7Be), are powerful atmospheric tracers of stratosphere–troposphere exchange (STE) processes; however, measurements are sparse for altitudes well above the tropopause. We present a novel high-altitude balloon campaign aimed to measure these isotopes in the mid-stratosphere called Beryllium Isotopes for Resolving Dynamics in the Stratosphere (BIRDIES). BIRDIES targeted gravity waves produced by tropopause-overshooting convection to study their propagation and impact on STE dynamics, including the production of turbulence in the stratosphere. Two custom-designed payloads called FiSH and GASP were flown at altitudes approaching 30 km to measure in situ turbulence and beryllium isotopes (on aerosols), respectively. These were flown on nine high-altitude balloon flights over Kansas, USA, in summer 2022. The atmospheric samples were augmented with a ground-based rainfall collection targeting isotopic signatures of deep convection overshooting. Our GASP samples yielded mostly negligible amounts of both 10Be and 7Be collected in the mid-stratosphere but led to design improvements to increase aerosol capture in low-pressure environments. Observations from FiSH and the precipitation collection were more fruitful. FiSH showed the presence of turbulent velocity, temperature, and acoustic fluctuations in the stratosphere, including length scales in the infra-sonic range and inertial subrange that indicated times of elevated turbulence. The precipitation collection, and subsequent statistical analysis, showed that large spatial datasets of 10Be/7Be can be measured in individual rainfall events with minimum terrestrial contamination. While the spatial patterns in rainfall suggested some evidence for overshooting convection, inter-event temporal variability was clearly observed and predicted with good agreement using the 3D chemical transport model GEOS-CHEM.
58 GEOSCIENCES↗